Archives of Foundry Engineering

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Description

Archives of Foundry Engineering continues the publishing activity
started by Foundry Commission of the Polish Academy of Sciences (PAN) in
Katowice in 1978. The initiator of it was the first Chairman Professor
Dr Eng. Wacław Sakwa – Corresponding Member of PAN, Honorary Doctor of
Czestochowa University of Technology and Silesian University of
Technology. This periodical first name was „Solidification of Metals and
Alloys” , and made possible to publish the results of works achieved in
the field of the Basic Problems Research Cooperation. The subject of
publications was related to the title of the periodical and concerned
widely understand problems of metals and alloys crystallization in a
casting mold. In 1978-2000 the 44 issues have been published. Since 2001
the Foundry Commission has had patronage of the annually published
“Archives of Foundry” and since 2007 quarterly published “Archives of
Foundry Engineering”. Thematic scope includes scientific issues of
foundry industry:

Abstract

The paper presents a research results concerning impact of volume
modification (ceramic filter containning cobalt aluminate and
hafniumpowder) and simultaneous surface and volume modification on
solidification and stereological parameters of macrostructure of
castingsmade from post-production scrap of nickel superalloy IN-713C.
Research included investigation of the influence of chemical
compositionon the temperature Tliq i Tsol and evaluation of following
macrostructure parameters: the number of grains per mm2, average grain
area andshape coefficient. Results indicate high influence of carbon
content on Tliq. Macrostructure of sample castings indicate positive
effect of surface and volume modification, however impact of surface
modification is more pronounced.

Abstract

Slag refining slag with west materials was analysed used the DTA
methods. In the paper a method of determining the reduction capability,
with the Carbo-N-Ox method, of slag solutions was used. Some relations between
the stimulators in the environment - slag - metal system
allow to initiate mass exchange reactions in the process of slag refining.The
presented in work course of behaviour permits on choice of
basic composition of slaglite, the of necessary components stimulating
quantities, as well as on accomplishment of opinion of ability
refinement. The worked out programme Slag-Prop, after introduction of data
with experiment, it allows on next corrections in composition
of proposed mixtures also, should be put on properly elaborated factors of
multistage reaction with essential usage of suitable stimulators.

Abstract

During the slag refining process, in the real systems, the complex
processes of mass exchange appear. Some relations between the
stimulators in the environment - slag - metal system allow to initiate mass
exchange reactions in the process of slag refining. Due to this
kind of influences there is a possibility of direction and control of melting
copper and it’s alloys.

Abstract

Mechanization of the process of core making with the use of inorganic
and organic binders is based, almost solely, on core blowing
machines. Presently the core blowing machines are equipped with tools and
devices that allow for application of different technologies
of core making. Cold-box, hot-box and warm-air technologies require that core
blowing machines shall be additionally equipped with
either core-box pre-heating system or gas purging and neutralization system,
or hot air purging systems.
Considering the possibility of using varied, the most advantageous
technologies of core making, the production of universal core blowing
machines equipped with replaceable devices has been undertaken in Poland. The
universal core blowing systems allow for mechanization
of core making process also with the use of sand, bonded by modern,
eco-friendly binder systems.
The paper presents selected results-based evaluation of core blowing process
showing the scope of conducted design and implementation
works.

Abstract

This paper presents the results of the abrasive wear resistance of
selected types of nodular cast iron, including ADI, cooperating with
quartz sand and 100 grit abrasive paper. It has been shown that carbides in
nodular cast iron cause an increase in wear resistance of 6 to
12% depending on the surface fraction of the carbides and type of the matrix.
For the same unit pressure the mass loss of the cast iron
cooperating with quartz sand is many times larger than the cast iron
cooperating with abrasive paper. For both abrasives the highest wear
resistance showed nodular cast iron with upper and lower bainite and carbides.

Abstract

The paper summarizes research realized by the author in laboratory and
industrial conditions (foundries of cast steel and cast iron, castings
up to 50 tons) on the effects of the chemically hardened molding sands
regeneration using hard/soft rubbing in the dry reclamation.
A reference was simultaneously made to advisability of application of the
thermal regeneration in conditions, where chromite amount in
the circulating (reclaimed) molding sand goes as high as above ten percent. An
advisability of connecting standard and specialized methods
of examination of the reclaimed sands and molding sands made using it was
pointed out. A way of application of studies with the Hot
Distortion Plus® method modified by the author for validation of modeling of
the thermo-dynamic phenomena in the mold was shown.

Abstract

One of the factors that contribute to the development of foundry moulding
technology is environmental protection. The related challenges
are effectively satisfied by a new inorganic binder that has been designed for
castings made of non-ferrous metal alloys.
This article presents in a concise way the test results, showing the
ecological character of the new binder at the stage of making moulds,
pouring them with metal and cooling of castings, indicating the possibilities
for an economic re-use of waste materials formed during
practical application of this technology. The results were compared with the
results obtained on the sands with organic binders.
Studies were carried out under the project POIG.01.01.02-00-015/09 "Advanced
materials and technologies."

Abstract

The paper presents the optimization of master alloy amount for the high
nodular graphite yield (80-90%) in cast iron obtain in lost foam
process. The influence of the gating system configuration and the shape of the
reaction chamber, the degree of spheroidisation cast iron
was examined. Research has shown that the, optimal of master alloy amount of
1.5% by mass on casting iron. The degree
of spheroidisation is also influenced by the gating system configuration. The
best spheroidisation effect was obtained for liquid cast iron
was fed into the reaction chamber from the bottom and discharged from the top.

Abstract

In the article we were studing the impact of the remelting on
transformations in Co-Cr-Mo prosthetics alloy. The TDA curves were
analyzed,
the microstructure was examined, the analysis of the chemical composition and
hardness using the Brinell method was made. It was
found that the obtained microstructure of the alloys that we studied do not
differ significantly. In all four samples, microscopic images
were similar to each other. The volume, size and distribution of the phases
remain similar. Analysis of the chemical composition showed
that all the samples fall within the compositions provided for the test alloy.
Further to this the hardness of the samples, regardless of the
number of remeltings did not show any significant fluctuations and remained
within the error limit.After analyzing all the results, it can be
concluded that the remeltings of the alloys should not have a significant
impact on their properties.
Secondarily melted alloys can be used for prosthetics works.

Abstract

Metal alloys with matrix based on an Fe-Al system are generally considered
materials for high-temperature applications. Their main
advantages are compact crystallographic structure, long-range ordering and
structural stability at high temperatures. These materials are
based on an intermetallic phase of FeAl or Fe3Al, which is stable in the range
from room temperature up to the melting point of 1240°C.
Their application at high temperatures is also beneficial because of the low
cost of production, very good resistance to oxidation and
corrosion, and high mechanical strength. The casting alloy the structure of
which includes the FeAl phase is, among others, highaluminium
cast iron. This study has been devoted to the determination of the effect of
vanadium and titanium on the transformation of the
high-aluminium cast iron structure into an in-situ FeAl-VC composite.

Abstract

The article presents issues related to creating and realizing added value
by logistic processes and processing in a casting enterprise.
It discusses possibilities of improving systems of casts production by
evaluating labour intensity of casts manufacture and analyzing
manufacturing prime costs. Operations with added value, processes indirectly
creating added value and operations without added value
have been specified. The problem was presented on the example of materials
flow design in a foundry, where casts are manufactured
in expendable moulds and using automated foundry lines. On the basis of the
Pareto analysis, a group of casts was specified whose
manufacture significantly influences the functioning of the whole enterprise.
Finishing treatment operations have been
particularly underlined, as they are performed away from the line and are
among the most labour-consuming processes during casts
production.

Abstract

Stereological description of dispersed microstructure is not an easy task
and remains the subject of continuous research. In its practical
aspect, a correct stereological description of this type of structure is
essential for the analysis of processes of coagulation
and spheroidisation, or for studies of relationships between structure and
properties. One of the most frequently used methods for an
estimation of the density Nv and size distribution of particles is the Scheil
- Schwartz – Saltykov method. In this article, the authors present
selected methods for quantitative assessment of ductile iron microstructure,
i.e. the Scheil - Schwartz – Saltykov method, which allows
a quantitative description of three-dimensional sets of solids using
measurements and counts performed on two-dimensional cross-sections
of these sets (microsections) and quantitative description of
three-dimensional sets of solids by X-ray computed microtomography, which
is an interesting alternative for structural studies compared to traditional
methods of microstructure imaging since, as a result, the analysis
provides a three-dimensional imaging of microstructures examined.

Abstract

The method of pressure die casting of composites with AlSi11 alloy matrix
reinforced with 10 vol. % of SiC particles and the analysis
of the distribution of particles within the matrix is presented. The composite
castings were produced at various values of the piston
velocity in the second stage of injection, at diverse intensification pressure
values, and various injection gate width values. The distribution
of particles over the entire cross-section of the tensile specimen is shown.
The index of distribution was determined on the basis of particle
count in elementary measuring fields. The regression equation describing the
change of the considered index was found as a function
of the pressure die casting parameters. The conclusion presents an analysis of
the obtained results and their interpretation.

Abstract

The paper presents the results of studies on the effect of the AlSi17Cu5
alloy overheating to atemperature of 920°C and modification with
phosphorus (CuP10) on the resultingmechanical (HB, Rm, R0.2) and plastic (A5
and Z) properties. It has been shown that, so-called, "timethermal
treatment" (TTT) of an alloy in the liquid state, consisting inoverheating the
metal to about 250°C above Tliq,holding at this
temperature by 30 minutes improvesthe mechanical properties. It has also been
found that overheating of alloy above Tliq.enhances
the process of modification, resulting in the formation of fine-grain
structure. The primary silicon crystals uniformly distributed in the
eutectic and characteristics ofthe α(Al) solution supersaturated with alloying
elements present in the starting alloy composition (Cu, Fe)
provide not only an increase of strength at ambient temperature but also at
elevated temperature (250°C).